Direct Drive Automated Hatch System for Hopper Railcars

ABSTRACT

An direct drive automated hatch system for a hopper rail car with a central longitudinal trough with coaming and a unitary hatch cover; a plurality of guide rail assemblies connecting one side of the top of the railcar perpendicular to and adjacent a corresponding longitudinal edge of the coaming to the hatch cover, wherein one guide rail assembly is positioned at each end of the trough and one or more guide rail assemblies are evenly spaced between the outermost guide rail assemblies; a cable network connecting the guide rail assemblies to the batch and external coaming of the trough; and means for activating the cable network to open and close the hatch and to align the opposing ends of the hatch cover during opening and closing. A hatch cover open/closed indicator visible from the side of the railcar is provided.

FIELD OF THE INVENTION

The present invention relates to railcars. In particular, the present invention relates to a pneumatically operated hatch system for trough loaded hopper railcars.

BACKGROUND OF THE INVENTION

It is known to provide trough loaded railway cars, which may be fitted with openable hatch covers to enclose the lop hatch opening, or ‘trough’.

Such hatch covers provide product containment. Other benefits include product protection, for example, protection from rain, snow, debris, or vermin. Many different granular or powdered products including grains may be shipped by railcar in this way.

Typically, such hatch covers are fastened onto railcars with various types of clamps or brackets which fix the twitch cover to tine car, preventing it from corning loose in transit, but which allow manual opening of the hatches.

Hatch covers typically may be manufactured of steel, aluminum, or various composite materials, each of which has its advantages and disadvantages. Manual hatch covers are typically built as several pieces, allowing them to be easily opened manually by a worker.

In order to open manual hatches, a worker must walk along running boards installed on live top of each railcar in order to reach the hatches. The worker will then unlock and open each hatch cover to prepare for loading or unloading and must repeat this process to close the manual hatches. This is a hazardous activity and is a major cause of injuries to workers.

Automatic hatch covers are a replacement for manual hatches and provide a method to reduce injuries by allowing the worker to open the hatches from trackside, or automatically without worker contact, avoiding the need for the worker to walk on the roof of the railcar. In addition, the time required to open the hatches is also reduced.

SUMMARY OF THE INVENTION

The present invention provides an automated hatch system for a hopper railcar having a central longitudinal trough with coaming, the system comprising a unitary hatch cover; a plurality of guide rail assemblies connecting one side of the top of the railcar perpendicular to and adjacent a corresponding longitudinal edge of the coaming to the hatch cover, wherein one guide rail assembly is positioned at each end of the trough and one or more guide rail assemblies are evenly spaced between the outermost guide rail assemblies; a cable network connecting the guide rail assemblies to the hatch and external coaming of the trough; means for activating the cable network to open and close the hatch and to align the opposing ends of the hatch cover during opening and closing.

Each guide rail assembly may comprise guide rails having a pair of profiled slots connected to the top of the railcar and parallel to and spaced apart from each other: an arm having internal and external ends, the internal end connected to the top of the hatch cover and the external end comprising four rollers which are movable within the guide slots.

The cable network may comprise a plurality of sheaves mounted on sheave brackets at each end of each guide rail assembly, and at the external comers of the trough coaming; a pair of cables running through the sheaves and fixed in place relative to the railcar.

The means for activating the cable network may comprise a pair of pneumatic cylinders; an alignment tube extending between the pneumatic cylinders; an alignment car movable between retracted and extended positions; a source of pressurized air; and actuator means, which may comprise an actuator button or levers.

BRIEF DESCRIPTION OF THE DRAWINGS

A detailed description of the preferred embodiment is provided below by way of example only and with reference to the following drawings in which:

FIG. 1 is a perspective view of the top of a railcar showing the automated hatch system of the present invention with the hatch cover in the open position;

FIG. 2 is a perspective view of the top of a railcar showing the automated hatch system of the present invention with the hatch cover in the closed position;

FIG. 3 is a perspective view of one end of the automated hatch system with the hatch cover in a closed position;

FIG. 4 is a perspective view of one end of the automated hatch system with the hatch cover in an open position;

FIG. 5 is a perspective view of the pneumatic cylinders and alignment system with the hatch in the closed position and alignment car retracted;

FIG. 6 is a perspective view of the pneumatic cylinders and alignment system with hatch open and alignment car extended;

FIG. 7 is a perspective view of the alignment car details; and

FIG. 8 is a side view of a guide rail assembly showing the guide slot and the open/close cable tension adjustment location in the arm;

FIG. 9 is a top view of the cable network during hatch opening and closing;

FIG. 10 is a perspective view of the open/close indicator trigger mechanism which contacts the hatch when closed; and

FIG. 11 is a perspective view of the open/close indicator visible to workers at ground level with a reflective paddle visible when the hatch open.

In the drawings, selected embodiments of the invention are illustrated by way of example. It is to be expressly understood that the description and drawings are only for the purpose of illustration and as an aid to understanding and are not intended as a definition of the limits of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention comprises a system for ripening and closing a hatch on trough loaded hopper railcars. According to an embodiment of the system of the present invention, there is provided a hatch cover for covering a trough loaded railcar. and bitch opening means for reversibly moving a hatch cover from a closed position atop a railcar to an open position alongside the trough. Coordinated operation of the system of the present invention may be achieved with one or more air cylinders and button or lever operated actuators. Preferably, two pneumatic cylinders at a single location on the hatch may be used to provide sufficient power to drive the automated hatch cover system of the invention. The air source for the air cylinders can be shared with the hopper gates on the railcar. Alternatively, air can be applied trackside for hopper cars with manual hopper gates that lack an available on-car source of air.

According to a preferred embodiment of the invention as demonstrated in the drawings, a unitary hopper railcar hatch cover is displaceable along a plurality of guide rail assemblies between a closed position sealing the trough, and an open position held adjacent the trough. Preferably, a guide rail assembly is provided at each longitudinal end of the hatch, and two additional guide rail assemblies are provided evenly spaced between the longitudinal ends, for a total of four guide assemblies. Fewer or more guide rail assemblies are possible within the scope of the invention.

Each guide rail assembly comprises a pair of profiled guide rails with a profiled slot. The guide rail assembly further comprises an arm attached to the top of the hatch cover and extending perpendicularly between the profiled guide rails. Each arm includes four rollers which run inside the slots on the guide rails.

In operation, when the system is actuated to remove the hatch cover from its closed position sealing the trough, a cable network is activated to move the hatch cover away from the trough and the guide rail slots cause the hatch cover to be lifted above the sill of the trough, to then be moved laterally clear of the trough, and finally lowered onto the top of the railcar in an open position adjacent to the trough. The guide rail assemblies repeat the lifting and sealing in reverse when the hatch cover is moved from the open position atop the railcar to the closed position sealing live trough. The curved slot of the profiled guide rail ensures the hatch cover is lifted free of the coaming upon opening and that a solid seal is formed between the hatch cover and the railcar upon closing.

The present invention moves the hatch cover completely clear of the trough, as may be best seen in FIG. 1. The guide rail assemblies of the present invention maintain the hatch cover within Plate C when fully open or fully closed. The hatch cover will briefly exceed Plate C during the opening and closing cycles.

The hatch cover is provided with a standard rubber seal similar to seals used on manual hatches. The guide rails and arms provide downward force on the hatch cover and seal in the closed position to generate a solid seal between the hatch cover and the top of the railcar. Additional security may be provided by incorporating a rod-lock feature in the air cylinders to prevent hatch opening in the event of air pressure loss.

The automated hatch system of the present invention may be activated by one of several means. According to a first embodiment, the system may have a manual air-input point at which external air may be quickly connected to operate the automated hatch system. According to a second embodiment, a push button or lever control may be provided at track level or may be incorporated into hopper controls. Preferably the system may include a simple discreet open/close button and a hidden security button which must be pressed simultaneously to operate the open/close button. According to a third embodiment, useful for high volume or automated operations, a roller may run along the top edge of the railcar tripping a paddle trigger to effect opening and closing of the hatch.

Hatch covers placed on railcars tend to be very long and narrow due to the shape of the top of a railcar. In other applications with a long hatch cover, hydraulics can be used to maintain an even operation. Generally speaking, only pneumatic systems are available in the railway environment, and pneumatics are very difficult to balance in this way. The result is one end of the hatch cover may move at a different rate as the other. This can cause hatch covers to fail or stick.

One aspect of the present invention is an alignment system which ensures that both ends of the hatch cover will move in an identical fashion. In addition, it makes it possible to drive a hatch cover from one location on the car, with no need to have an additional mechanism or air supply at another location. As noted in the drawings, a single drive location is employed in the preferred embodiment of the present invention.

A prior art version of the present technology utilizes a passive alignment system to move both ends of the hatch cover simultaneously to avoid failure or sticking. In contrast, the present invention utilizes a direct drive alignment system using one or two cylinders to manipulate a single drive cable which splits off to connect to each of the four arms, allowing direct drive movement of each arm to ensure coordinated simultaneous movement of the entire hatch cover. An offset is provided to allow the cable to remain clear of each cylinder.

The means for activating the cable network may comprise a pair of pneumatic cylinders; an alignment tube extending between the pneumatic cylinders; an alignment car movable between retracted and extended positions; a source of pressurized air; and actuator means, which may comprise an actuator button or levers.

As best seen in FIG. 9, according to one embodiment, the cable alignment system includes two cable networks involved with each hatch cover, an opening cable network and a closing cable network. In both cases, the cables will run through sheaves attached to the guide rails and attach directly to the arms. Additional sheaves may be located on the ends of the trough coaming on the end sheave brackets. The cable network is adjustable with tensioners located inside each arm which adjusting opening and closing cable length.

The present invention includes an alignment car and cylinder alignment system which permits use of one or two pneumatic cylinders to manipulate the cable, and an offset to allow the cable to clear each of the cylinders. The alignment system maintains the two cylinders and their rods in alignment while the loads are offset by approximately 6 inches by operation of the alignment tube and alignment car, as depicted in FIGS. 5 to 7. The alignment car runs beside the alignment tube and includes a pair of slide blocks which run inside the alignment tube.

In operation, one or more pressurized air cylinders are used to operate the cable network, manipulating all the arms at an equal pace and with equal force to ensure the hatch moves evenly to avoid hatch failure or sticking.

The hatch system is not visible to a worker on the ground. An open/closed indicator may be located on one end of the railcar, visible from the ground, to allow a worker to see whether the hatch is open or fully closed without having to view the hatch directly. As depicted in FIG. 11, the open/closed indicator may comprise a pivoting flag movable between a closed position within an adjacent sleeve, and an open position separated from the adjacent sleeve. A control cable may be used to effect movement of the pivoting flag between open and closed positions.

The automated hatch system of the present invention may be retrofit to existing equipment with removal of an existing man-walk on only one side of the railcar. 

1. An automated hatch system for a hopper railcar having a central longitudinal trough with coaming, the system comprising: a. a unitary hatch cover; b. a plurality of guide rail assemblies connecting one side of the top of the railcar perpendicular to and adjacent a corresponding longitudinal edge of the coaming to the hatch cover, wherein one guide rail assembly is positioned at each end of the trough, one or more guide rail assemblies are evenly spaced between the outermost guide rail assemblies, and each guide rail assembly comprises i. a linear guide rail having a linear slot connected to the top of the railcar; ii. a profiled guide rail having a curved slot connected to the top of the railcar, the profiled guide rail parallel to and spaced apart from the corresponding linear guide rail; and iii. an arm having internal and external ends, the internal end connected to the top of the hatch cover and the external end comprising a first roller on one side of the arm movable within the linear slot and a second roller on the opposing side of the arm movable within the curved slot, c. An opening cable network connecting the guide rail assemblies to the hatch and external coaming of the trough; d. A closing cable network connecting the guide rail assemblies to the hatch and external coaming of the trough; and e. means for activating the cable networks to open and close the hatch and to align the opposing ends of the hatch cover during opening and closing.
 2. The hatch system of claim 1 wherein each of the opening and closing cable networks comprises: a. a plurality of sheaves mounted on sheave brackets at each end of each guide rail assembly, at the comers of the hatch cover, and at the external corners of the trough coaming; b. a cable running through the sheaves and fixed in place relative to the railcar; and c. a plurality of cable adjustment turnbuckles disposed along the cable network.
 3. The hatch system of claim 1, wherein the means for activating the cable network comprises: a. at least one pneumatic cylinder; b. an alignment tube extending between the pneumatic cylinders; c. an alignment car movable along the alignment tube between retracted and extended positions; d. a source of pressurized air; and e. actuator means.
 4. The hatch system of claim 3, wherein the actuator means comprises an actuator button.
 5. The hatch system of claim 3, wherein the at least one pneumatic cylinder comprises two pneumatic cylinders. 